Search Results (665)

Based on the E5018 zirconia–alkali low hydrogen iron powder electrode as the base composition, this paper incorporates nano-rare earth CeO₂ powder into the coating. Using the orthogonal experimental method, a total of nine groups of experiments were established, each with four factors and three levels. These factors include (A) nano-rare earth CeO₂ powder at levels of 1.1%, 1.3%, and 1.6%; (B) iron powder at levels of 30%, 35%, and 40%; (C) fluorite at levels of 6%, 8%, and 10%; and (D) zirconium quartz at levels of 5%, 7%, and 9%. The arc combustion stability of the welding rod is determined by an arc analyzer, and the formation and slag removal of the weld seam are evaluated by wide slope welding. Welding a spatter is evaluated by an observation method. The range and variance of the orthogonal experiment results were calculated, and the process performance was studied and analyzed. The results indicate that samples No. 1, 4, 5, 7, and 9 demonstrate superior performance in the welding process, specifically in terms of arc stability, weld formation, slag detachment, and spatter. The addition of nano-rare earth CeO₂ powder has the most significant impact on weld formation, while iron powder, fluorite, and zirconium quartz have notable effects on arc stability, spatter, and slag detachment, respectively. The optimal combination of these four factors at three levels for optimal welding process performance is A2B1C2D3, with the recommended amounts being 1.3% of nano-CeO₂ powder, 30% of the iron powders, 8% of fluorite, and 9% of zirconium quartz. Full article

Real-time management of short-term ozone peaks during arc welding remains challenging because ventilation- and enclosure-defined transport boundaries can create strong position-dependent peak behavior, even under fixed process settings. This study establishes a coordinate-referenced, event-level monitoring and analysis framework to quantify ozone–fume peak coupling under a controlled local exhaust ventilation (LEV) suction boundary during CO₂ arc welding. A controlled process–environment testbed with a defined suction condition was implemented, and synchronized ozone and fume signals were acquired at three sampling points referenced to the arc position and the LEV inlet direction. The particulate channel was anchored to a PM₄ gravimetric reference, yielding a condition-specific traceable CPM-to-mass conversion factor K₁ of 1.76 × 10⁻² mg/(m³·CPM) and enabling standardized peak-fume endpoints on a mass-concentration scale. The primary inferential analysis used the curtain-on dataset, comprising 21 sessions and 42 event-level records balanced across three sampling points. Under the same suction boundary, peak coupling was strongly monitoring-coordinate dependent: LEV-aligned locations showed statistically supported ln–ln scaling between peak ozone and peak fume, whereas the opposite-side location did not exhibit statistically supported scaling; a pooled point-parameterized ln–ln model achieved an adjusted R² of 0.777. As a descriptive control-relevant contrast, adding a curtain enclosure under continuous LEV produced strong event-level ozone peak suppression at LEV-aligned locations, with a maximum reduction of 87.8%, while attenuation at the opposite-side location remained limited. Overall, the results provide a ventilation-boundary-consistent, coordinate-specific basis for monitoring placement and control evaluation, identifying where peak translation is supported and where direct ozone monitoring remains necessary. Full article

To investigate the effect of welding speed on the out-of-plane deformation of Q420 low-alloy high-strength steel thin plates, this study employed a three-dimensional digital image correlation system to monitor the deformation dynamically during TIG welding and cooling. Unlike existing studies that mostly focus on post-weld residual deformation or a single welding stage, this study, under a fixed current of 36 A and arc voltage of 14 V, sets welding speeds ranging from 4.5 to 11.8 mm/s, and for the first time systematically reveals the complete evolution path of Q420 thin plate (2 mm) welding deformation, which includes “thermal expansion—instability mutation—elastic rebound—residual stabilization”. The results show that the welding speed is significantly negatively correlated with the out-of-plane deformation. Although low-speed welding has a high peak plastic strain, the final residual strain is almost completely released; while high-speed welding has a low peak strain but retains a relatively high residual strain. This abnormal phenomenon reveals the deep mechanism that the accumulation and release of plastic strain are asymmetrically regulated by the welding speed. These findings support process optimization for high-strength steel thin plates. Full article

Duplex stainless steel (DSS) blends impressive mechanical and chemical characteristics to withstand aggressive environments. Its fabrication by Gas Metal Arc Welding-Additive Manufacturing is an emerging research topic. However, its sensitive grain structure and alloy composition are prone to deterioration by repeated thermal shocks. Whether optimal weld parameters can resolve these challenges without additional costs from special fillers, gases, or mechanisms is a valid question. In this study, how different wire feed speeds, travel speeds, and weld voltages, chosen from a set of preliminary beads, translate into wall dimensions, phase formation and distribution, morphological transformation, and elemental segregation is investigated. The unique DSS microstructures were characterised using scanning electron microscopy and energy-dispersive spectroscopy to reveal differences in microstructural evolution and ferrite-austenite (α-γ) structure. The deposited walls exhibited satisfactory geometric quality with negligible distortions. However, the height suppression was noticeable at the deposition energy (DE) of 755 J/mm. Metallographic analysis revealed low γ phase formation (<30%) at low DE (230 J/mm) and excessive γ formation (>70%) in the high DE wall (755 J/mm). The parameters WFS:TS = 15, TS = 35 cm/min, WFS = 525 cm/min, and V = 20.804 volts suppressed the elemental segregation while maintaining a suitable phase balance without post-processing. Full article

This study presents a mathematical and kinematic modeling framework for analyzing trajectory behavior in a virtual reality (VR) welding simulator. Twenty novice participants performed repeated welding trials across three sessions, with torch trajectories recorded at 50 Hz in the task space. The proposed framework combines trial-level performance descriptors with derivative-based dynamic features, including spectral arc length (SPARC), log-normalized jerk (LNJ), and the number of velocity peaks (NVP), to characterize movement smoothness, intermittency, and longitudinal trajectory organization in a computer-simulated manual welding task. The results showed that spatial welding error decreased most clearly during the earliest stage of practice, with mean absolute lateral error declining from approximately 2.8 mm in the first trial to approximately 1.7 mm by the third trial. This early improvement was then broadly preserved across subsequent sessions. In contrast, smoothness- and fragmentation-related metrics exhibited more variable temporal patterns, indicating that improvements in task-space accuracy were not necessarily accompanied by uniform reorganization of movement dynamics. Associations between spatial error and kinematic features remained limited, suggesting that geometric task accuracy and dynamic trajectory organization represent complementary aspects of simulated manual performance. Overall, the findings show that high-frequency trajectory analysis in VR provides a useful basis for the mathematical modeling of dynamic behavior in simulated welding systems and supports the use of computer simulation for process-level investigation of manual task execution. Full article

Wire arc additive manufacturing (WAAM) is an efficient, low-cost technique for fabricating large-scale metallic components and, in particular, functionally graded materials (FGMs). This review focuses on the fabrication of 316L stainless steel–Inconel 625 FGMs by arc-based WAAM processes, examining Gas Metal Arc Welding (GMAW), Gas Tungsten Arc Welding (GTAW) and Plasma Arc Welding (PAW) in terms of their microstructural outcomes, compositional control strategies, residual stress development and mechanical performance. A critical finding emerging from the reviewed literature is that direct compositional interfaces between 316L and Inconel 625 can yield superior tensile strength and ductility and lower residual stresses compared to smooth gradient strategies, owing to the formation of detrimental secondary phases such as δ-phase, Laves phase and MC carbides at intermediate iron–nickel compositions encountered only during graded builds. The potential of Submerged Arc Additive Manufacturing (SAAM) as a future high-deposition-rate alternative for large-scale FGM fabrication is also discussed. Key challenges, including dilution control, Laves phase formation, residual stress management and the corrosion characterization of the graded region, are identified, together with priority research directions for advancing the industrial adoption of arc-based FGM components. Full article

Wire Arc Additive Manufacturing (WAAM) has emerged as a promising additive manufacturing technique due to its high deposition rate and low material cost. WAAM is increasingly adopted in various industries for the production of large-scale metal components, yet optimizing productivity without sacrificing mechanical integrity remains a critical challenge, particularly for low-carbon steels. This study systematically investigates the influence of key WAAM parameters—welding current (100–350 A) and travel speed (5–30 mm/s) on the deposition stability, microstructure, and mechanical properties of thin walls made of low-carbon Fe–0.09 C–1.10 Cr–1.47 Mn–0.59 Si–0.56 Mo–0.11 Ni–0.23 V steel. A stable processing window for defect-free wall fabrication was established for currents of 100–250 A, while higher currents of 300–350 A resulted in melt pool instability and geometrical distortions due to excessive heat input. Microstructural characterization revealed a dual-phase structure consisting of allotriomorphic ferrite (ALF) and acicular ferrite (AF) in all samples. The microstructural evolution was critically governed by variations in the cooling time in the critical temperature range of 800 °C to 500 °C (t_8/5) within the thermal cycles, a direct consequence of the heat input quantified through volumetric energy density. Low heat input at 100 A, 5 mm/s promoted a microstructure with minimal ALF fraction of ~10%, whereas high heat input at 350 A, 30 mm/s induced significant ferrite recrystallization and coarsening, increasing ALF fraction to ~55%. These microstructural changes directly affected mechanical properties: YS/UTS decreased from 512 MPa/668 MPa to 401 MPa/602 MPa, respectively. Concurrently, the deposition rate increased substantially from ~1.6 kg/h to ~6.3 kg/h. The results demonstrate a critical trade-off between productivity and mechanical performance, providing a practical framework for parameter selection in WAAM-fabricated low-carbon steel components. Full article

To solve the problems of poor weld formation, difficult slag removal, and inferior joint microstructure and hardness in conventional narrow-gap submerged arc welding (NG-SAW), a swing arc NG-SAW process assisted by pre-embedding cold wires was proposed. Synergistically optimizing the welding energy parameters and additional cold wires ensured sound weld formation and enhanced slag detachability, while the efficiency of multilayer welding was improved by reducing the number of weld layers by 33.3%. The slag adhesion mechanism is clarified as follows: a high welding heat input facilitates elemental diffusion at the weld–slag interface, leading to the formation of a continuous and thick interlayer composed of (Fe,Mn)O and MgO-Al₂O₃-CaO phases. This interlayer strengthens the chemical bonding between slag and weld, thereby impeding slag removal. Microstructure evolution analysis of the multilayer welded joint revealed that the variable-angle design increases the groove volume and, combined with the heat-absorbing effect of the additional wires, accelerates molten pool cooling, thereby refining grains in both the weld metal zone and reheat-affected zone. Meanwhile, the tempering exerted by the heat-affected zone (HAZ) of the subsequent weld layer on the previous layer is attenuated. This promotes the gradual transformation of hard-brittle lath martensite in the coarse-grained heat-affected zone (CGHAZ) of the bottom layer into tougher tempered martensite/bainite in the CGHAZ of the upper layers. As a result, the hardness uniformity within the HAZ, the critical weak region of the joint, was enhanced by 54%, enabling synchronous improvement in microstructural homogeneity, hardness distribution, and overall welding efficiency. Full article

This study quantitatively evaluates the impact of Wire Arc Additive Manufacturing (WAAM) process parameters on the environmental performance of components produced in Invar 36 alloy. An experimental campaign involving 49 parameter sets was carried out by varying wire feed speed, welding voltage, and welding speed. For each condition, electrical signals, shielding gas consumption, and wire usage were measured and converted into parameter-resolved Life Cycle Inventory (LCI) data. A cradle-to-gate Life Cycle Assessment (LCA) was implemented in SimaPro 9.6 using the European CML-IA baseline v3.10 midpoint method, adopting 1 kg of as-built deposited Invar 36 as the functional unit. Results show that feedstock production represents the dominant hotspot (8.68 kg CO₂-eq/kg), while the WAAM stage contributes between 1.13 and 4.12 kg CO₂-eq/kg, leading to a total impact ranging from 9.81 to 12.80 kg CO₂-eq/kg. As a result, this study demonstrates that process parameter selection strongly influences environmental performance. Indeed, Specific Energy Consumption (SEC) ranges from 0.44 to 1.95 kWh/kg, while argon consumption varies between 0.26 and 1.51 kg/kg of deposited material. By analysing the results and excluding unstable or manufacturing-infeasible deposition regimes, the optimal trade-off between process stability and environmental impact is achieved at approximately WFS = 7 m/min, V = 20 V, and WS = 6.5 mm/s. Beyond quantifying the environmental hotspots of Invar 36 WAAM, this study provides a dedicated, parameter-resolved cradle-to-gate LCA based on experimentally measured foreground data collected across 49 process parameter combinations. By combining environmental assessment with feasibility screening of the investigated deposition regimes, the work identifies not only environmentally favourable conditions, but also parameter regions that are technologically viable for WAAM processing of Invar 36. The resulting dataset provides a benchmark foundation for future sustainability-oriented process optimisation and decision support in WAAM. Full article

This study investigates the feasibility of acoustic signal analysis for the assessment of weld bead quality in the shielded metal arc welding (SMAW) process. The work focuses on comparing time-domain acoustic signals and time–frequency spectrogram representations for the classification of welds as accepted or rejected according to standard welding inspection criteria. Two key acoustic descriptors, the fundamental frequency (F₀) and the harmonics-to-noise ratio (HNR), were extracted and analyzed to evaluate statistical differences between the two weld quality classes. Statistical tests, including Anderson–Darling, Levene, ANOVA, and Kruskal–Wallis (α = 0.05), revealed significant differences between accepted and rejected welds. Accepted welds exhibited a bimodal HNR distribution associated with transient arc instability at the beginning and end of the bead, whereas rejected welds showed more uniform acoustic behavior throughout the process. Subsequently, the acoustic data were represented using both audio signals and spectrograms and used as inputs for ten supervised machine learning models, including Support Vector Classifier (SVC), Logistic Regression (LR), k-Nearest Neighbors (KNN), Decision Tree (DT), Random Forest (RF), Extra Trees (ET), Gradient Boosting (GB), and Naïve Bayes (NB). The results demonstrate that spectrogram-based representations significantly outperform time-domain signals, achieving accuracies of 0.95–0.96, ROC-AUC values above 0.95, and false positive and false negative rates below 6%. These findings indicate that, while scalar acoustic descriptors provide statistically significant insight into weld quality, time–frequency representations combined with machine learning enable a more robust and reliable framework for automated non-destructive evaluation, particularly in manual SMAW processes under realistic operating conditions. Full article

This study evaluates the feasibility of acoustic signal analysis using different spectrographic transformation methods as a tool for assessing the quality of welding beads produced through the Shielded Metal Arc Welding (SMAW) process. Acoustic emissions were recorded during manual welding operations under controlled experimental conditions, using E6013 electrodes on A36 carbon steel plates. From the acoustic recordings of 400 welding samples, previously classified as accepted or rejected, two fundamental acoustic descriptors were extracted: the fundamental frequency (F₀) and the harmonic-to-noise ratio (HNR). These were analysed using parametric and non-parametric metrics to evaluate their discriminative capability. In addition, multiple supervised classifiers were trained and validated using stratified eight-fold cross-validation. The proposed framework enables a systematic comparison of different signal transformations and classification models for the evaluation of SMAW welding quality. Among the evaluated models (SVC, Gradient Boosting, and Extra Trees), precision rates of 90–95% were observed using Spectral Contrast, MEL, and CQT transformations. The results demonstrate that the implementation of various acoustic signal-based models and transformations for welding inspection offers a scalable and cost-effective solution for industrial quality control. Full article

Welding fumes in the shipbuilding industry severely threaten workers’ health. This study systematically investigated welding fume exposure in a Chinese shipyard, analyzing mass concentration, particle size distribution, and harmful metal content using data from 2015. Differences were observed across welding sites and processes. Confined spaces and gas metal arc welding (GMAW) were associated with significantly higher exposure levels. Welding fumes were dominated by particles smaller than 1.00 μm, a distribution influenced by welding site, distance from the welding spot, and process. Iron (Fe) and manganese (Mn) were the predominant metal components, with concentrations significantly higher in respirable dust than in total dust. Risk assessment indicated minimal non-cancer hazards for Fe, zinc, and copper. However, Mn posed the predominant risk (Hazard Quotient >> 1), while nickel (Ni) and chromium (Cr) also exceeded safety thresholds at most points. Consequently, confined spaces and GMAW should be prioritized as key control targets in shipyards, as respirable dust rich in metal-bearing particles poses greater health risks. Therefore, China urgently requires the establishment of specific occupational exposure limits for respirable welding fumes. Additionally, personal sampling is more focused and efficient than area sampling for precise occupational health risk assessment due to the greater mobility of welding operations. Full article

High-entropy alloy (HEA) coatings are widely recognized for their excellent hardness and wear resistance. Heterogeneous cabled wire welding (HCWW) combined with gas metal arc welding (GMAW) has emerged as an efficient approach for fabricating HEA coatings; however, severe arc instability inherent to HCWW often deteriorates coating quality. In this study, the effects of axial magnetic fields (AMFs) with different orientations on the HCWW–GMAW process were systematically investigated. High-speed imaging revealed that the HCWW arc without magnetic assistance exhibits pronounced instability, characterized by asymmetric morphology and rotational behavior. The application of AMFs significantly altered arc dynamics. An upward axial magnetic field (N-AMF, 2 mT) effectively suppressed arc rotation, resulting in a stable bell-shaped arc and more uniform heat input, whereas a downward axial magnetic field (S-AMF) caused arc contraction and promoted dendrite coarsening. Consequently, the N-AMF condition led to a refined and homogeneous microstructure, yielding a high microhardness of 825 ± 15 HV. Tribological tests demonstrated that the wear rate of the N-AMF-assisted coating was reduced by 55% compared with that produced by conventional GMAW. These results highlight that magnetic-field-induced arc stabilization plays a critical role in achieving high-performance HEA surface coatings. Full article

This paper examines the use of metallurgical process waste in welding electrode coatings and their impact on the quality and properties of welded joints in carbon steels. The results demonstrate that the use of metallurgical process waste in slag coatings for welding electrodes can significantly reduce the cost of the charge without degrading the welding properties of the electrodes or the quality and properties of the welded joints. The new electrode under study was fabricated using technological waste of metallurgical plants for the welding electrodes (IMAN-9). An activator additive consisting of nanostructured functional ceramics ZB-1 was introduced into the coating at an amount of 1% to increase the melting capacity of the welding electrode. This electrode is characterized by low cost, good welding properties, and ensures high-quality welded joints and beads. This paper also includes comparative tests of welded joints in low-carbon AISI 1017 steel using the IMAN-9 electrode and the ESAB E6013 electrode, which is widely used in the global market. Research has shown that IMAN-9 electrodes, compared to ESAB E6013 electrodes, offer superior performance in terms of weld metal penetration, weld metal structure, and weld joint ductility. In terms of strength, welds made by the IMAN-9 electrodes are slightly inferior to those made by the ESAB E6013 electrodes. Full article

The geometric variability of industrial components represents a persistent challenge in robotic arc welding, particularly in high-volume manufacturing environments where parts are positioned in fixtures based on nominal CAD assumptions. Even moderate deviations in dimensions or seating conditions can lead to weld defects, rework, and reduced process capability when conventional offline programming is employed. This paper presents an applied industrial workflow for adaptive robotic welding trajectory correction that integrates full-field 3D optical metrology with a data-driven deep reinforcement learning (DRL) model. Prior to welding, each component is scanned using a structured-light 3D system, and critical geometric deviations are extracted relative to the nominal CAD model. These deviations define a compact state representation that is mapped, via a trained DRL agent, to corrective translational and rotational adjustments of the welding trajectory. Importantly, all trajectory corrections are computed offline, ensuring compatibility with standard industrial robot controllers and avoiding real-time computational overheads. The proposed approach is validated using real production data from an industrial batch of 5000 components characterized by significant dimensional variability and limited process capability. Experimental results demonstrate a reduction in welding defects exceeding 90%, elimination of rework associated with improper part positioning, and an improvement of the overall process performance to a sigma level of 5.219. The results show that combining 3D optical metrology with learning-based trajectory adaptation enables robust compensation of part-level geometric deviations without mechanical fixture modifications. The proposed method provides a practical and scalable solution for improving welding quality in manufacturing environments affected by upstream variability and imperfect part positioning. Full article